Apparatus for continuously molding chocolate products

ABSTRACT

Methods for continuously molding finished chocolate tablets, pieces and the like are disclosed. Apparatus for use with the method, comprise a chilled rotating mold having at least one recess into which liquid chocolate is deposited. Liquid chocolate, is held in place by a retaining/casting belt as the rotating mold turns. The liquid chocolate cools and partially sets while in contact with the rotating mold and retaining/casting belt, and a molded chocolate is removed from the recess. Novel finished chocolate molded products made by the methods and with the apparatus, having detailed surface design and surface gloss are also disclosed.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to the molding of chocolate. Specifically,the disclosed method and apparatus are directed to the continuousmolding of chocolate tablets, pieces and the like on a rotary mold.

[0003] 2. Discussion of the Related Art

[0004] Finished chocolates having a desired three-dimensional shape orhaving an image or design imprinted on a surface are conventionallyproduced by molding, and are herein referred to as “molded chocolate.”The finished chocolate may be a solid block, a hollow shell, or a shellfilled with a confectionery material such as fondant, fudge or softcaramel (Chocolate, Cocoa and Confectionery: Science and Technology byBernard W. Minifie, Third Edition, page 183, herein incorporated byreference in its entirety). Whatever the particular form of the finishedchocolate, all are characterized by attributes such as detailed finishesand high surface gloss. Further, these finished chocolates do notrequire further processing such as enrobing with chocolate, which onlyprovides a home-made look to a product and lacks high gloss and finesurface detail.

[0005] Conventional molding typically employs very large numbers ofmolds, usually made of polycarbonate. These polycarbonate molds aretypically flat, approximately 1 inch in height and anywhere from 1 to 2feet long and 1 to 5 feet in width.

[0006] The equipment employed to manipulate and process these molds isvery large and among the most complex and expensive of all confectioneryproduction equipment. Mold changeover and mold tooling are alsoexpensive and often make it costly to produce a large variety of shapedchocolate products.

[0007] In the typical conventional molding process a chocolate mixtureis initially melted at temperatures of about 45° C. and tempered bycooling with agitation to about 29° C. to 30° C. to produce a temperedchocolate. The tempering of the chocolate causes a very small percentageof the fat to form seed crystals which results in a dispersion of theseseed crystals throughout the liquid fat phase of the liquid chocolate.The liquid tempered chocolate is then deposited into a polycarbonatemold. The mold is shaken to remove air bubbles and to distribute thechocolate in the mold cavity. These steps are critical to reproducingthe detail of the mold surface and to obtaining a glossy finishedproduct surface. Indeed, if the chocolate viscosity is too high or hasbecome significantly partially solidified, the resultant finishedchocolate product appearance will be poor. Defects such as air bubbleson the surface, poor gloss and poor or incomplete surface detail areencountered. Thus, to properly mold finished chocolates, it is essentialthat the final chocolate structure is only developed after filling themolds (i.e., the chocolate must still be liquid when the chocolate isdeposited into the molds.)

[0008] The mold and chocolate are then cooled and the chocolatehardened, and finally, the set, shaped chocolate is removed from themold. Removing the chocolate from the mold usually involves turning themolds upside down and deforming them slightly, or striking the mold sothat the molded chocolate falls out under its own weight.

[0009] These methods place limitations on the size, shape and finish ofthe final product, and on production efficiency. Conventional chocolatemolding processes are among the slowest confectionery productionprocesses for the amount of equipment and space involved. A goodproduction rate would be about 15-20 molds per minute, very good about20-25 molds per minute and excellent about 25-30 molds per minute. Toachieve these high levels of production requires great attention to theprocess.

[0010] Another significant limitation to the molding of finishedchocolate products is related to the size of the products. It has longbeen known in the art that small molded chocolate pieces, on the orderof 0.5 grams and smaller, cannot be reliably demolded and this has hadthe practical effect of limiting confectioners to relatively largerpieces. This problem results from the ratio of surface area in contactwith the mold to the mass of the piece being too high in these smallpieces. Demolding processes essentially rely on gravity to help removethe pieces from the molds. This is true even in cases where molds aretapped or hammered and in cases where flexible molds might be employed.The smaller mass of a small chocolate piece means less gravitationalforce to overcome the attractive forces holding the piece into the mold.Thus, a process which provided for continuously molding very smallfinished chocolate pieces or the like would be a highly desirableadvancement in the art.

[0011] Processes for continuously molding food products have beendisclosed in the prior art, but these processes do not provide for theproduction of finished molded chocolate.

[0012] U.S. Pat. No. 4,059,378, for example, discloses a method ofcontinuously molding chocolate centers, hot sugar masses, fudge, whippedor unwhipped chewing or nougat mass, candy cream and the like whichavoids the need for an extruder. These “center” materials are notsubject to the same functional requirements as molded chocolate. Thereis no disclosure of feeding liquid chocolate to the recesses on themold, and as a practical matter the invention is limited to centermanufacture.

[0013] The methods and apparatus described in U.S. Pat. No. 4,059,378 donot provide a means to continuously set and mold chocolate tablets,pieces, or the like because the process will not provide an appropriatefinish or texture of a finished molded chocolate piece.

[0014] Significant functional requirements are demanded of moldedchocolate that are not required of centers. The surface of moldedchocolate must typically have detailed surface design and glossy finish.The formation of a suitably solidified design with an appropriatelyglossy finish cannot be performed in a shaping apparatus such asdescribed in U.S. Pat. No. 4,059,378. The apparatus and method of U.S.Pat. No. 4,059,378 are specifically directed towards the molding ofconfectionery masses, such as the centers or nougat masses and the likespecifically noted in the patent. The apparatus and method utilizeessentially set confectionery masses, which are then formed by means ofan “intake cylinder being operable to press the mass into the moldingrecesses of the molding cylinder.” Clearly the masses are substantiallyset or solidified, and the patent emphasizes the need for a “gentlemolding process which does not impair the original structure of themass.”

[0015] By clear contrast, molding processes for finished moldedchocolate pieces require the use of liquid chocolate which flows readilyinto mold cavities and does not have structure. It is the ability ofliquid chocolate to flow into mold cavities which ensures good surfacedetail, good gloss and proper final product texture (i.e., good “snap.”)

[0016] Published U.K. Pat. Application GB 2,337,387 A describes a methodand apparatus for molding food articles. In this method, chocolatehalves simultaneously formed in two discrete rollers are pressedtogether and united in the “nip” between the two rollers. This inventionis a further refinement of the long-known technique of roll-formingcenters which typically are further processed by panning to applychocolate coatings or hard sugar shell coatings. The product of thesemold-forming techniques does not provide the high quality attributes offinished molded chocolate pieces. In fact, the product of GB 2,337,387is a sheet of chocolate articles connected by a continuous web ofchocolate which must be removed in an abrasive process known asdeflashing. The deflashing process abrades the surface finish of thechocolate articles leaving a rough unfinished appearance. The result isa complex feeding and removal mechanism of uncertain utility.

[0017] Other processes describe molding of finished chocolates but donot employ rotary techniques. For example, published InternationalApplication WO98/30111, the entire disclosure of which is incorporatedherein by reference, describes methods for shaping chocolate productswhich involve contacting a chocolate composition with a chilled formingdevice. This application does not describe continuous molding on arotary mold.

SUMMARY OF THE INVENTION

[0018] The inventors herein have discovered a method for continuouslymolding finished chocolate pieces which comprises:

[0019] (a) feeding liquid chocolate into a recess in the surface of acooled rotating mold having an interior cavity;

[0020] (b) providing a coolant having a temperature less than about 10°C. to said interior cavity to lower the temperature of said recess;

[0021] (c) containing the liquid chocolate in the recess with aretaining/casting belt that maintains the liquid chocolate in the recessuntil the liquid chocolate sets to become at least partially solidifiedmolded chocolate; and

[0022] (d) removing the molded chocolate from the recess.

[0023] The ratio of surface area of the chocolate in contact with thecooled rotating mold to the surface area of chocolate in contact withthe retaining/casting belt is generally less than about 4.5:1.Preferably, this ratio is less than about 3.5:1, more preferably lessthan about 3:1 and most preferably less than about 2:1.

[0024] In one aspect, the method of the present invention comprisesallowing the liquid chocolate to contact a cooled recess in a rotatingmold for a period of time such that the surface of the chocolate setssufficiently, and the piece can be efficiently removed from the rotatingmold, while an interior portion of the chocolate piece remains morefluid until after the chocolate piece is removed from the rotary mold.In another aspect, the method of the present invention provides themeans for producing small finished molded chocolate pieces in a reliableand efficient manner. The setting of the chocolate while in contact withthe retaining/casting belt creates a strong attractive force between thechocolate piece and the belt. As the retaining/casting belt separatesfrom the rotary mold, this force effectively demolds the small piece.

[0025] An apparatus for continuously molding chocolate productsaccording to the invention comprises: a substantially cylindrical rotarymold having an interior cavity and having at least one recess on anexterior radial surface portion of the rotary mold. The rotary moldrotates as coolant is provided to its interior cavity maintaining thetemperature on a surface of the recess to a temperature approaching thetemperature of the coolant, less than about 10° C. As the mold rotates,a feeder deposits liquid chocolate into said recess; and aretaining/casting belt positioned to maintain the liquid chocolatedeposited in said recess moves in unison with the rotational motion ofthe rotary mold. The opening of the recess has an area, and the ratio ofsurface area of the chocolate in contact with the cooled rotating moldto the surface area of the chocolate in contact with theretaining/casting belt is less than about 4.5:1, preferably less than3.5:1, more preferably less than 3:1 and most preferably less than 2:1.It is expected that the higher ratios would require increasing thecooling time on the rotary mold, or using lower cooling temperatures. Topermit removal of the molded chocolate from the recess, a sidewall ofsaid recess makes an angle of greater than about 7 degrees with respectto a line perpendicular to the radial surface of the rotary mold.Additionally, as the liquid chocolate solidifies in contact with theretaining/casting belt, it is essentially cast into the surface contoursof the belt, providing a transient bonding of the chocolate to the belt,allowing easy demolding.

BRIEF DESCRIPTION OF THE FIGURES

[0026]FIG. 1 depicts an apparatus according to an embodiment of theinvention.

[0027]FIG. 2 depicts a system of cams in cooperation with the rotarymold and retaining/casting belt according to an embodiment of theinvention.

[0028]FIG. 3 depicts a system of cams in cooperation with the rotarymold and retaining/casting belt according to an embodiment of theinvention in a state wherein a molded chocolate piece has been removedfrom the wheel.

[0029]FIG. 4 depicts a shoe used to feed liquid chocolate into a recessaccording to an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] The term “chocolate” is intended to refer to all chocolate orchocolate-like compositions with a fat phase or fat-like composition. Asthe invention is directed in certain aspects to the control of thecharacteristics of the fat or fat-like phase of the chocolate, ratherthan the non-fat materials within the chocolate, the term is intended toinclude all chocolate and chocolate-like compositions. The term isintended, for example, to include standardized and non-standardizedchocolates, i.e., including chocolates with compositions conforming tothe U.S. Standards Of Identity (SOI) and compositions not conforming tothe U.S. Standards Of Identity, respectively, including dark chocolate,baking chocolate, milk chocolate, sweet chocolate, semi-sweet chocolate,buttermilk chocolate, skim-milk chocolate, mixed dairy productchocolate, low fat chocolate, white chocolate, aerated chocolates,compound coatings, non-standardized chocolates and chocolate-likecompositions, unless specifically identified otherwise.

[0031] In the United States, chocolate is subject to a standard ofidentity established by the U.S. Food and Drug Administration (FDA)under the Federal Food, Drug and Cosmetic Act. Definitions and standardsfor the various types of chocolate are well established in the U.S.Nonstandardized chocolates are those chocolates which have compositionswhich fall outside the specified ranges of the standardized chocolates.

[0032] Chocolates also include those containing crumb solids or solidsfully or partially made by a crumb process.

[0033] Nonstandardized chocolates result when, for example, thenutritive carbohydrate sweetener is replaced partially or completely; orwhen the cocoa butter or milkfat are replaced partially or completely;or when components that have flavors that imitate milk, butter orchocolate are added or other additions or deletions in formula are madeoutside the FDA standards of identify of chocolate or combinationsthereof.

[0034] For use with the apparatus disclosed herein, the only requirementof the chocolate is that it be liquid and (if the chocolate is atempering system) tempered as it is fed to the rotary mold.

[0035] As shown in FIG. 1, the liquid tempered chocolate is pumped fromchocolate feed 1 into recess 3 on rotating hollow mold 5 at the top ofthe rotating hollow mold 5. The mold is, generally speaking,cylindrical. The “top” of rotary mold 5 means the top half of the rotarymold 5. Preferably, the feed will be located at a position between 10o'clock and 2 o'clock with respect to the rotary mold. Most preferably,chocolate will be fed into the recess directly above the mold, i.e. atthe 12 o'clock position, as shown in FIG. 1. A second feeder can beprovided to co-deposit materials in the recess with the liquidchocolate.

[0036] The recess may be one continuous groove, as shown in FIG. 1, inwhich case the resulting molded chocolate would be removed from therotary mold in one continuous strip, or discrete recesses can beprovided, resulting in discrete molded chocolate pieces.

[0037] The surface of the recess 3 is cooled, for example with a coolantprovided in the interior of rotating mold 5. In preferred embodiments,the coolant is propylene glycol, although a commercial coolant such asSyltherm®, available from Dow Chemical, or even a brine solution couldalso be used. Preferably, coolant continuously circulates through thesystem. Additionally, coolant may be provided in an area proximate theretaining/casting belt, for example in a cavity underneath theretaining/casting belt as further described below. If cooling throughthe retaining/casting belt is desirable, the belting material can bechosen from among materials having higher thermal conductivity.

[0038] The surface of the recess 3 and the rotating mold 5 are bothpreferably made of metal to enable better heat transfer from the liquidchocolate to the coolant. For example, mold 5 may be of polishedaluminum, nickel-plated steel, chromium-plated copper, silver platedcopper, or other material. The specific material is not particularlylimited, provided that the surface of the recess can be maintainedreliably at the desired temperature that is, at a temperatureapproaching that of the coolant. Working embodiments have used an 8 inchdiameter aluminum wheel polished to an 8 micron finish, however, thesize can vary depending upon the size of product and the rate ofproduction required.

[0039] The surface of the recess is generally smooth, although portionsof the surface may be etched or machined to make a design which will beimpressed or raised on the finished chocolate product. In a preferredembodiment the recess is a continuous groove, which may have a design,and the chocolate product that is removed from the belt is a continuousstrip, which may then be cut into discrete pieces by a guillotine cutter9.

[0040] Liquid chocolate is fed into recess 3 at a temperature betweenabout 27° C. and about 32° C., most preferably at about 30° C. At thistemperature, tempered chocolate will have the required fluidity forchocolate molding.

[0041] In preferred embodiments, as shown in FIG. 3, a “shoe” isprovided between the feeder and the rotary mold to facilitate thefeeding of liquid chocolate to the recess. The shoe comprises a body 15,typically made of a metal, such as aluminum. The body is attached tocontact surface 13, which may be made of a low friction material, forexample, Teflon® (polytetrafluoroethylene). The contact surface is incontact with the rotary mold in a sealing relationship. In FIG. 4, thecontact surface is shown separated from the rotary mold to allow aclearer view. Liquid chocolate is fed through sanitary fitting 17 intothe recess. The use of a shoe in this manner avoids the necessity ofhaving to meter precise amounts of liquid chocolate into the recesses asthe rotary mold rotates.

[0042] The chocolate cools and partially solidifies in contact with therotating mold. The temperature of the surface of the rotary mold ismaintained by providing a coolant to an interior cavity of said rotarymold having a temperature between about −40° C. and about +10° C., andpreferably between about −20° C. and about +5° C., and most preferablybetween about −5° C. and about 0° C. Preferably, the surface of themolded chocolate solidifies allowing the chocolate to achieve sufficientintegrity for removal from the rotary mold, while the interior of themolded chocolate may remain more fluid.

[0043] To obtain the glossy surface that is typically demanded of afinished molded chocolate piece, the chocolate must be liquid when it ispoured into the mold to obtain the required smooth surface.

[0044] In some embodiments it is be desirable to perform transientheating of the recess 3 just prior to depositing liquid chocolate intothe recess. Heating, such as with a stream of hot air, an infra-redheater, or other means known to those of skill in the art, is sufficientto raise the surface temperature of the recess temporarily to about 5°C., 10° C., 15° C. or 20° C., as desired. Warming the recess in thismanner can improve surface gloss of the molded chocolate. In anotherembodiment of the invention, where non-tempering chocolate is beingmolded the non-tempering chocolate can be introduced at a highertemperature to improve the gloss of the finished molded chocolate. Thisalso helps to maintain chocolate fluidity during the molding process.

[0045] The time allowed for the chocolate to cool and solidify to apoint where it can be removed from the rotary mold is determined by thesize of the mold, the speed at which it turns, the volume of chocolatein the recess, the surface temperature of the recess, and the rate ofheat transfer from the chocolate as it cools and solidifies. Generally,between about 20 and about 60 seconds is necessary to partially set thechocolate, preferably between about 25 and about 50 seconds, mostpreferably between about 30 and about 45 seconds.

[0046] Thus, the size of mold 5 is itself not particularly critical,provided that the chocolate has sufficient time to become sufficientlysolidified. The size of the wheel and its speed of rotation may beadjusted to provide a partially set chocolate to be removed from therotary mold.

[0047] As the mold rotates, the recess is partly covered with aretaining/casting belt 7 that tracks and runs in unison with therotating mold 5. While the mold preferably rotates continuously inunison with the retaining/casting belt, the mold and belt may alsorotate in a uniform interrupted manner with liquid chocolate only beingfed to the mold during the rotational period. The retaining/casting beltacts as a containment device to retain the liquid chocolate in therecess of the mold while it sets and casts to the belt. The belt may bemade of, for example, plastic, fiber-plastic composite or metal. Theretaining/casting belt may be cooled by providing a continuouslycirculating coolant to cavity 11 below the retaining/casting belt at aportion of the belt positioned downstream of the rotary mold. Theretaining/casting belt may also be machined or etched to provide adesign on the surface of the finished chocolate bar or piece facing theretaining/casting belt.

[0048] Finished molded chocolate is removed from the recess 3 onto thebelt 7. The condition of the chocolate as it is removed is important. Ifthe chocolate has not sufficiently set, then the bar or piece will notretain its integrity. Preferably, the chocolate removed from the recess3 has an average temperature of less than about 25° C., more preferablyless than about 22° C. and most preferably between about 15° C. andabout 20° C. The temper of the chocolate as well as its fat content willdetermine the temperature at which the chocolate obtains a sufficientlyintegral state permitting removal from the rotary mold. In someembodiments, the retaining/casting belt is maintained in a pressingrelationship with the partially set chocolate in the recess after therecess advances past the 6 o'clock position. The adhesion of the belt tothe chocolate in the recess as the belt pulls away from the rotary moldcreates a perpendicular force on the partially set chocolatefacilitating its removal from the recess. Any suitable means may beprovided to maintain the retaining/casting belt in contact with therotary mold in this fashion. A cam 19 situated under theretaining/casting belt in the vicinity of the rotary mold, for example,may periodically force the belt against the wheel and then release,while another cam 21 takes up slack in the retaining/casting beltcreated by this movement, as shown in FIGS. 2 and 3. A system of camsoperating with the belt in this manner keeps the belt in contact withthe chocolate past the 6 o'clock position, allowing for improved removalof the chocolate, owing to the greater force available for removal ofthe chocolate at that position.

[0049] In connection with the temperature of the molded chocolate as itis removed from the rotary mold, by “average temperature” is meant atemperature that would be measured by a temperature probe if the probewere inserted into the chocolate and the chocolate piece were allowed toequilibrate insulated from the environment.

[0050] The recess must also be sized so that the chocolate can beremoved from the recess. As with conventional chocolate moldingtechniques, a release angle of greater than about 7 degrees from thevertical is generally provided to permit the chocolate to slide out ofthe recess. More preferably, the release angle of the recess used inconnection with the rotary mold will be greater than about 8 degrees.Most preferably, the release angle will be greater than about 10degrees.

[0051] In some instances the product may be removed from the wheel as acontinuous web of chocolate, which may be textured. In some preferredembodiments, a thin web produced in this manner has a thickness on theorder of {fraction (1/32)} inch (0.08 cm) up to about ¼ inch (0.635 cm),and has a lace-like pattern made up of chocolate and empty spaces.Highly-designed, non-random and readily-reproducible chocolatestructures can be made according to the invention. The artisan willappreciate that a molded chocolate web having these characteristicscannot be molded using conventional techniques.

[0052] Within these general parameters, the depth of the recess is notparticularly limited and is generally between about {fraction (1/32)}inch (0.08 cm) and about 1 inch (2.54 cm). Likewise, the width of therecess may vary widely, up to 2 inch (5.08 cm) or more. Workingembodiments have used a recess ⅜ inch (0.95 cm) deep by 1 inch (2.54 cm)wide. One of the advantages of the continuous molding method of thepresent invention is that pieces having a greater ratio of width tothickness, and having finer overall structural detail can be easilyobtained, as compared with the prior art.

[0053] The temperature of the recess and speed of rotation of the rotarymold are set to obtain a partially solid (plastic) chocolate stripexiting the bottom of the mold. The continuous strip may then be cutinto desired lengths by guillotine cutter 9, further cooled inconventional cooling tunnels, and packaged. However, as mentioned above,the size of the recess is not particularly limited and instead of acontinuous strip, the finished chocolate may be in the form of discretepieces.

[0054] Generally, an apparatus according to the invention will have adehumidifier proximate the wheel and retaining/casting belt to conditionthe air around the molding chocolate. Cooling means underneath theretaining/casting belt, as described above, further set the chocolateafter it is removed from the rotary mold.

[0055] Generally, in some instances, it will be necessary to providefurther thermal conditioning of the molded chocolate pieces to ensureproper stability of the fat phase. For example, cocoa butter basedchocolate may require conditioning in a “cooling” tunnel after demoldingto allow proper crystal formation, thus ensuring bloom stability. Suchconditioning also allows any more liquid regions in the center of amolded piece to fully and properly solidify. Most preferred temperatureconditioning comprises cooling at between about 15° C. and about 18° C.for about 10 minutes.

[0056] Products made according to the methods of the present invention,and molded using the apparatus according to the invention, includechocolate pieces having uniform composition throughout and made from asingle deposition into a rotary mold. Other products according to theinvention are products in which different types of chocolate (such aslight and dark chocolate), or chocolate in combination with other foodmaterials are co-deposited from the same or different sources into therotary mold. Other variations and modifications that would be apparentto one of ordinary skill in the art are considered within the scope ofthe appended claims.

EXAMPLES

[0057] The following examples are illustrative of some of the productsand methods of making the same falling within the scope of the presentinvention. They are, of course, not to be considered in any way limitingof the invention. Numerous changes and modifications can be made withrespect to the invention within the scope of the appended claims.

Example 1

[0058] DOVE® Milk Chocolate, a commercially available milk chocolate,was melted and tempered in a Savage Bros. Co. Batch Tempering System.The chocolate was cooled from 45° C. to 28° C. to produce cocoa buttercrystals of stable and unstable polymorphs. The tempered chocolate wasthen warmed slightly to 31° C. to melt out the unstable crystals. Thetempered chocolate was at 31° C. and had a temper level of 6 CTU (° F.)and −0.5 slope as determined by Tricor Tempermeter Model 501. Thechocolate was then pumped to the rotary molding device.

[0059] The rotary molding device consisted of an 8 inch diameter,metallic wheel, which was cooled with coolant having a temperature of 5°C. and rotated at 0.435 rpm. A groove was cut into the wheel withoverall dimensions of 1 inch wide and ⅜ inch deep and a wall taper of7°. The chocolate was fed into the groove through a pipe fitted flushagainst the rotating wheel. The chocolate was contained in the groove bya solid, polyurethane-coated belt, which was wrapped against, androtated concurrent with, the rotating wheel from the 12 o'clock positionto the 6 o'clock position. At the 6 o'clock position, the solidchocolate strip released from the wheel and was carried away from thewheel on the conveyor belt. The continuous chocolate strip was then cutinto sections to form a chocolate bar. The belt carried the chocolatebar over a platen under the conveyor belt that was cooled to −10° C. byrecirculating cooling media The platen set the bottom of the chocolatebars so they would release from the belt. The bars were then transferredto a Sollich cooling tunnel.

[0060] The cooling tunnel was comprised of one section with an airtemperature of 15° C. The residence time in the tunnel was 10 minutes.The resultant finished chocolate bar exiting the tunnel had a fair togood glossy, bloom stable surface.

Example 2

[0061] Chocolate comprised as set forth in Example 1 was pumped to themolding device as comprised in Example 1 with the exception of thegroove in the wheel. In this example, a grid design was cut into thewheel with an array spacing of ¼ inch by ½ inch. The wheel rotated at0.9 rpm and produced a finished product which was a precision moldedregular loose mesh. The resultant finished chocolate mesh exiting thetunnel had a fair to good glossy, bloom stable surface.

Example 3

[0062] Chocolate comprised as set forth in Example 1 was pumped to themolding device as comprised in Example 1 with the exception of thegroove in the wheel. In this example, the groove was cut to overalldimensions of 2 inches wide and ¼ inch deep with a 7° wall taper. Thewheel rotated at 0.9 rpm and was supplied with coolant having atemperature of 1° C. The resultant finished chocolate exiting the tunnelhad a fair to good glossy, bloom stable surface.

Example 4

[0063] Chocolate comprised as set forth in Example 1 was pumped to themolding device as comprised in Example 1 with the exception of thegroove in the wheel. In this example, individual cavities were cut intothe wheel to resemble an “M&M's”® Brand Character. The wheel rotated at1.6 rpm and was supplied with coolant having a temperature of −10° C.The resultant finished chocolate pieces exiting the tunnel had a fair togood glossy, bloom stable surface.

We claim:
 1. A method for continuously molding finished chocolate piecescomprising: (a) feeding liquid chocolate into a recess in a surface of acooled rotating mold having an interior cavity; (b) providing a coolanthaving a temperature less than about 10° C. to said interior cavity tolower the temperature of said recess; (c) containing the liquidchocolate in said recess with a continuous retaining/casting belt thatmaintains the liquid chocolate in the recess until the liquid chocolatesets or solidifies to become at least partially solidified moldedchocolate; and (d) removing said molded chocolate from said recess ontosaid retaining/casting belt.
 2. The method according to claim 1 ,wherein a ratio of surface area of said chocolate in contact with saidcooled rotating mold to surface area of said chocolate in contact withsaid retaining/casting belt is less than about 4.5:1.
 3. The methodaccording to claim 1 , wherein a sidewall of said recess makes an angleof greater than about 7 degrees with respect to a line perpendicular toa radial surface of said rotating mold.
 4. The method according to claim1 , wherein said liquid chocolate is fed into said recess at atemperature between about 27° C. and about 32° C.
 5. The methodaccording to claim 1 , wherein said molded chocolate is removed fromsaid recess at an average temperature less than about 25° C.
 6. Themethod according to claim 5 , wherein said molded chocolate is removedfrom said recess at an average temperature between about 15° C. andabout 20° C.
 7. The method according to claim 1 , wherein said coolantprovided to said rotating mold has a temperature between about −5° C.and about 0° C.
 8. The method according to claim 1 , wherein saidcoolant provided to said rotating mold delivers a surface temperature ofsaid recess just before said feeding of liquid chocolate substantiallyequivalent to the temperature of said coolant.
 9. The method accordingto claim 1 , wherein said step of providing coolant to said rotatingmold comprises flowing a coolant through the cavity in said rotatingmold.
 10. The method according to claim 9 , wherein said coolantcomprises propylene glycol.
 11. The method according to claim 1 ,wherein said recess is between about {fraction (1/32)} inch (0.08 cm)and about 1 inch (2.54 cm) deep.
 12. The method according to claim 5 ,wherein the molded chocolate is removed from the rotary mold when thechocolate in a surface portion of said molded chocolate is solidifiedwhile the chocolate in an interior portion of said molded chocolate ispartially solidified.
 13. The method according to claim 5 , wherein saidliquid chocolate resides in said recess for between about 30 and about45 seconds.
 14. The method according to claim 1 , wherein said recess isa continuous groove, and molded chocolate is removed from saidcontinuous groove in the form of a continuous molded strip.
 15. Themethod according to claim 14 , further comprising the step of cuttingsaid continuous molded strip into discrete pieces.
 16. The method ofclaim 1 , further comprising co-depositing a second food material intosaid recess at the same time that said liquid chocolate is in saidrecess.
 17. The method of claim 16 , wherein said second food materialis chocolate.
 18. The method of claim 1 , wherein said recess is heatedto provide a transient temperature increase of between 5° C. and 20° C.in said recess prior to said step of feeding said liquid chocolate intosaid recess.
 19. The method of claim 1 , further comprising subjectingsaid molded chocolate to thermal conditioning after said step ofremoving said molded chocolate from said recess.
 20. The method of claim1 , wherein said step maintaining said retaining/casting belt in contactwith said molded chocolate in said recess comprises a system of cams incontact with said retaining/casting belt after said molded chocolate haspassed a 6 o'clock position of the rotary mold, thereby increasing aforce available to remove said molded chocolate from said recess.
 21. Acontinuously molded chocolate product produced by the method of claim
 1. 22. A continuously molded chocolate product produced by the method ofclaim 1 , having a shape of a continuous and precise web, between about{fraction (1/32)} inch (0.08 cm) and ¼ inch (0.635 cm) thick.
 23. Acontinuously molded chocolate product produced by the method of claim 1, having a glossy surface.
 24. A continuously molded chocolate productproduced by the method of claim 1 , having a surface design imparted bya design on a surface of the recess in the rotary mold.
 25. An apparatusfor continuously molding chocolate products comprising: a hollowsubstantially cylindrical rotary mold having an interior cavity andhaving at least one recess on a radial surface portion of said rotarymold, said recess having an opening and a surface area; a motor toimpart rotational motion to said substantially cylindrical rotary mold;conduits leading to and from said interior cavity for connecting saidinterior cavity with a coolant source; a feeder for depositing liquidchocolate to said recess; a retaining/casting belt positioned tomaintain said liquid chocolate within said recess and adapted forcontinuous motion in unison with said rotational motion of said rotarymold; wherein said opening has an area and the ratio of the surface areaof the recess to the area of the opening is less than about 3:1, andwherein a sidewall of said recess makes an angle of greater than about 7degrees with respect to a line perpendicular to said radial surface ofsaid rotary mold.
 26. The apparatus of claim 25 , further comprising asecond cavity proximate said retaining/casting belt, and conduitsleading to and from said second cavity to continuously circulate coolantto and from said cavity capable of reducing the temperature of saidretaining/casting belt.
 27. The apparatus of claim 25 , wherein saidrotary mold has a metallic surface.
 28. The apparatus of claim 25 ,wherein said at least one recess is a single continuous groove.
 29. Theapparatus of claim 25 , further comprising a system of cams adapted tomaintain said retaining/casting belt in contact with said chocolatewithin said recess after said chocolate in contact with saidretaining/casting belt passes a 6 o'clock position of said rotary mold.